WO1997025938A1 - Improved ptfe vascular graft and method of manufacture - Google Patents

Improved ptfe vascular graft and method of manufacture Download PDF

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Publication number
WO1997025938A1
WO1997025938A1 PCT/US1997/001720 US9701720W WO9725938A1 WO 1997025938 A1 WO1997025938 A1 WO 1997025938A1 US 9701720 W US9701720 W US 9701720W WO 9725938 A1 WO9725938 A1 WO 9725938A1
Authority
WO
WIPO (PCT)
Prior art keywords
ptfe
tubular structure
porosity
tubular
vascular prosthesis
Prior art date
Application number
PCT/US1997/001720
Other languages
English (en)
French (fr)
Inventor
David J. Lentz
Jamie Henderson
Edward J. Dormier
Richard J. Zdrahala
Original Assignee
Meadox Medicals, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Meadox Medicals, Inc. filed Critical Meadox Medicals, Inc.
Priority to JP9526318A priority Critical patent/JPH11504548A/ja
Priority to DE69733122T priority patent/DE69733122T2/de
Priority to AT97904915T priority patent/ATE293935T1/de
Priority to CA002243951A priority patent/CA2243951C/en
Priority to EP97904915A priority patent/EP0879029B1/de
Priority to AU17582/97A priority patent/AU711304B2/en
Publication of WO1997025938A1 publication Critical patent/WO1997025938A1/en

Links

Classifications

    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L27/00—Materials for grafts or prostheses or for coating grafts or prostheses
    • A61L27/50—Materials characterised by their function or physical properties, e.g. injectable or lubricating compositions, shape-memory materials, surface modified materials
    • A61L27/56—Porous materials, e.g. foams or sponges
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F2/00—Filters implantable into blood vessels; Prostheses, i.e. artificial substitutes or replacements for parts of the body; Appliances for connecting them with the body; Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
    • A61F2/02—Prostheses implantable into the body
    • A61F2/04—Hollow or tubular parts of organs, e.g. bladders, tracheae, bronchi or bile ducts
    • A61F2/06—Blood vessels
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L27/00—Materials for grafts or prostheses or for coating grafts or prostheses
    • A61L27/14—Macromolecular materials
    • A61L27/16—Macromolecular materials obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L27/00—Materials for grafts or prostheses or for coating grafts or prostheses
    • A61L27/50—Materials characterised by their function or physical properties, e.g. injectable or lubricating compositions, shape-memory materials, surface modified materials
    • A61L27/507—Materials characterised by their function or physical properties, e.g. injectable or lubricating compositions, shape-memory materials, surface modified materials for artificial blood vessels
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F2/00—Filters implantable into blood vessels; Prostheses, i.e. artificial substitutes or replacements for parts of the body; Appliances for connecting them with the body; Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
    • A61F2/0077—Special surfaces of prostheses, e.g. for improving ingrowth
    • A61F2002/0086—Special surfaces of prostheses, e.g. for improving ingrowth for preferentially controlling or promoting the growth of specific types of cells or tissues
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F2/00—Filters implantable into blood vessels; Prostheses, i.e. artificial substitutes or replacements for parts of the body; Appliances for connecting them with the body; Devices providing patency to, or preventing collapsing of, tubular structures of the body, e.g. stents
    • A61F2/02—Prostheses implantable into the body
    • A61F2/04—Hollow or tubular parts of organs, e.g. bladders, tracheae, bronchi or bile ducts
    • A61F2/06—Blood vessels
    • A61F2/07—Stent-grafts
    • A61F2002/072—Encapsulated stents, e.g. wire or whole stent embedded in lining
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S623/00—Prosthesis, i.e. artificial body members, parts thereof, or aids and accessories therefor
    • Y10S623/901—Method of manufacturing prosthetic device

Definitions

  • the present invention relates generally to a tubular implantable prosthesis such as vascular grafts and endoprostheses formed of porous poiytetrafluorethyiene. More particularly, the present invention relates to a multi-layered tubular vascular graft or endoprosthesis formed from expanded poiytetrafluorethyiene.
  • PTFE polytetrafluor-ethylene
  • PTFE polytetrafluor-ethylene
  • ePTFE expanded poiytetrafluorethyiene
  • Grafts formed of ePTFE have a fibrous state which is defined by interspaced nodes interconnected by elongated fibrils. The spaces between the node surfaces that is spanned by the fibrils is defined as the internodal distance (IND).
  • IND internodal distance
  • a graft having a large IND enhances tissue ingrowth and cell endothelization as the graft is inherently more porous.
  • the art is replete with examples of microporous ePTFE tubes useful as vascular grafts.
  • the porosity of an ePTFE vascular graft can be controlled by controlling the IND of the microporous structure of the tube. An increase in the IND within a given structure results in enhanced tissue ingrowth as well as cell endothelization along the inner surface thereof.
  • tubular graft structures exhibiting enhanced radial tensile strength, as well as enhanced axial tear strength, these structures all result in tubes exhibiting lower porosity. More specifically, the multi-layered ePTFE tubular structures of the prior art exhibit a smaller microporous structure overall, especially at the inner surface, and accordingly, a reduction in the ability of the graft to promote endothelization along the inner surface.
  • ePTFE vascular graft which exhibits increased porosity especially at the inner surface thereof while retaining a high degree of radial strength especially at the external surface thereof.
  • the present invention provides an implantable poiytetrafluorethyiene (PTFE) vascular graft.
  • the graft includes a first ePTFE tubular structure, and a second ePTFE tubular structure circumferentially disposed exteriorly about the first tubular structure.
  • the porosity and physical strength characteristics of each of he aforementioned tubular structures can be varied independently of each other. This results in a structure whose first ePTFE tubular structure exhibits a porosity sufficient to promote cell endothelization there along, while the second structure exhibits strength in excess of the strength of the first tubular structure.
  • the first ePTFE tubular structure exhibits strength in excess of the strength of the second tubular structure, while the second tubular structure exhibits a porosity sufficient to promote more rapid tissue incorporation.
  • the first and second PTFE tubular structures are formed of expanded poiytetrafluorethyiene (ePTFE). Further, the second ePTFE tubular structure is adheringly supported over the first ePTFE tubular structure to form a composite tubular graft. The strength of this adhesion can be varied as desired to control the characteristics exhibited by the resultant composite structure.
  • ePTFE expanded poiytetrafluorethyiene
  • the present invention provides a method of forming a vascular graft.
  • the method includes the steps of providing a first ePTFE tubular structure having a desired porosity and strength combination.
  • a second ePTFE tubular structure is provided, also having the desired porosity and strength combination.
  • the second ePTFE structure is disposed over the first ePTFE so as to define a composite vascular graft
  • the method of the present invention also provides for the positioning of an intermediate structure between the first and second ePTFE tubular structures. Examples of such structures include an additional ePTFE layer and fibers or thin films of PTFE or other suitable polymers. This intermediate structure also contributes to the resultant porosity and strength ofthe vascular graft.
  • Figure 1 is a schematic longitudinal cross-section of a multi-layer ePTFE vascular graft of the present invention.
  • Figure 2 is a longitudinal cross-section of an alternate embodiment of the present invention producing a multi-layer ePTFE vascular graft.
  • Figure 3 is a scanning electron micrograph showing a cross-sectional view of a vascular graft produced using the present invention.
  • Figure 4 is a perspective showing of one of the tubular structures of the graft of Figure 1 over-wrapped with a layer of ePTFE tape.
  • Figure 5 is a cross-sectional showing of an alternate embodiment of the ePTFE vascular graft of the present invention. In this instance, the view is taken through the lines II-II of the view shown in Figure 2.
  • the prosthesis of the preferred embodiments of the present invention is a multi-layered tubular structure which is particularly suited for use as an endoprosthesis or vascular graft.
  • the prosthesis is formed of extruded poiytetrafluorethyiene (PTFE) as PTFE exhibits superior biocompatability. Further, PTFE is particularly suitable for vascular applications as it exhibits low thrombogenicity. Tubes formed of extruded PTFE may be expanded to form ePTFE tubes where the ePTFE tubes have a fibrous state which is defined by elongated fibrils interconnected by spaced apart nodes. Such tubes are said to have a microporous structure, the porosity of which is determined by the distance between the surfaces of he nodes, referred to as the internodal distance (IND).
  • IND internodal distance
  • Tubes having a large IND generally exhibit long term patency as the larger pores promote cell endothelization along the inner blood contacting surface.
  • Tubes having lower IND exhibit inferior healing characteristics, however they offer superior radial tensile and suture retention strengths desirable in a vascular graft.
  • the present invention provides a composite tubular structure which promotes long term patency of the graft by providing for enhanced cell endothelization along the inner surface while exhibiting enhanced strength due to the presence of the outer layer.
  • Graft 10 is a elongate tubular structure formed of
  • Graft 10 includes a pair of coaxially disposed ePTFE tubes 12 and 14, tube 12 being the outer tube and tube 14 being the inner tube.
  • a central lumen 15 extends through composite graft 10, defined further by the inner wall 14a of inner tube 14, which permits the passage of blood through graft 10 once the graft is properly implanted in the vascular system.
  • Each tube 12 and 14 may be formed in a separate extrusion process.
  • the process for the paste extrusion of PTFE tubes is well known in the extrusion art.
  • the tubes are expanded to form ePTFE tubes.
  • the tubes are expanded using differing process parameters (rates, deformation levels, temperatures, etc) to develop the desired microporous structures.
  • the specifically designed structure ofthe resulting composite tube has defined properties of strength and porosity which yield a graft 10 having long term patency and good healing characteristics as well as superior strength characteristics.
  • the present invention is designed to produce grafts with substantially different node/fibril structures with respect to the internal and external portions of the graft which are adjacent to the internal and external graft surfaces.
  • the inner tube 14 is designed to have relatively high IND while the outer tube 12 is designed to have a lower IND. Further, a distinct porosity change is clearly defined at the interface 13 between tubes 12 and 14. The inner tube 14 having a higher IND to allow enhanced ceil endothelization, while the outer tube 12 having a lower IND provides superior strength to the overall composite.
  • FIG. 3 An electron micrograph of such a structure produced according to the present invention is shown in Figure 3.
  • the disparate IND's between the inner tube 14 and outer tube 12 are clearly evident, along with the step change in IND at the interface 13 between the inner tube 14 and outer tube 12.
  • the strength of the interface 13 has been established by the processing conditions described below to fully adhere the inner tube 14 and outer tube together, hence preventing relative motion and providing enhanced strength.
  • Graft 10 ofthe present invention may be formed by expanding a thin wall inner tube 14 at a relatively high degree of elongation, on the order of approximately between 400 and 2000% elongation preferably from about between 700% and 900%.
  • Tube 14 is expanded over a cylindrical mandrel (not shown), such as a stainless steel mandrel at a temperature of between room temperature and 645°F, preferably about 500°F.
  • Tube 14 is preferably but not necessarily fully sintered after expansion. Sintering is typically accomplished at a temperature of between 645 °F and 800 °F preferably at about 660 °F and for a time of between about 5 minutes to 30 minutes, preferably about 15 minutes.
  • the combination of the ePTFE tube 14 over the mandrel is then employed as a second mandrel, over which outer tube 12 is expanded.
  • the ID of the outer tube 12 is selected so that it may be easily but tightly disposed over the OD of inner tube 14.
  • the composite structure 10 is then sintered at preferably similar parameters.
  • the level of elongation of outer tube 12 is lower than that of inner tube 14, approximately between 200% and 500% elongation preferably about 400%.
  • the expansion and sintering of outer tube 12 over the inner tube 14 serves to adheringly bond the interface 13 between the two tubes, resulting in a single composite structure 10.
  • the resulting composite structure has an inner surface defined by inner tube 14 which exhibits an IND of between 40 and 100 microns, spanned by moderate number of fibrils.
  • Such microporous structure is sufficiently large so as to promote enhanced cell endothelization once blood flow is established through graft 10.
  • Such cell endothelization enhances the long term patency of the graft
  • the outer structure defined by outer tube 12, has a smaller microporous structure, with IND of 15-35 microns and a substantial fibril density. Such outer structure results in an increase in the strength of the outer tube, and hence of the composite structure. Importantly, the outer surface defined by the outer tube 12 exhibits enhanced suture retention due to the smaller IND.
  • the resulting composite structure exhibits a sharp porosity change between the outer tube 12 and inner tube 14.
  • This sharp porosity transition is achieved by providing an inner tube 14 having generally a given uniform porosity therealong and then providing a separate outer tube 14 having a resultant different porosity uniformly therealong.
  • a distinct porosity change is exhibited on either side of he interface 13 defined between inner tube 14 and outer tube 12.
  • the strength ofthe interface between the two tubes may be independently varied through selection of processing conditions and relative dimensions of precursor extruded tubes 12 and 14 as desired to yield a range of performance.
  • a thin extruded tube having wall thickness of 0.41 mm and an inner diameter of 6.2 mm was expanded over a stainless steel mandrel at 500 °F to 900% elongation.
  • the ePTFE tube was then sintered at 660 °F for 14 minutes, cooled, and removed from the oven.
  • a second thin extruded tube having wall thickness of 0.45 mm and an inner diameter of 6.9 mm was expanded over the first tube/mandrel combination at 500 °F and 400% elongation.
  • the composite was then sintered at 660 °F for 14 minutes, cooled and removed from the oven.
  • the resultant composite tube had a wall thickness of 0.65 mm and ID of 5.8 mm.
  • a thin extruded tube having wall thickness of 0.41 mm and an inner diameter of 6.2 mm was expanded over a stainless steel mandrel at 500°F to 700% elongation.
  • the ePTFE tube was then sintered at 660 °F for 14 minutes, cooled, and removed from the oven.
  • a second thin extruded tube having wall thickness of 0.45 mm and an inner diameter of 6.9 mm was expanded over the first tube at 500 °F and 400% elongation.
  • the composite was sintered at 660 °F for 14 minutes, cooled, and removed from the oven.
  • the resultant composite tube had a wall thickness of 0.67 mm and an inner diameter of 5.8 mm.
  • Table I presents physical property data for a vascular graft of the type depicted in Example I described above.
  • the composite graft was removed from tbe mandrel and subjected to standard testing of radial tensile strength and suture hole elongation.
  • the radial strength of the 900%/400% composite graft is equivalent to a single layer 400% elongation graft and substantially stronger than a single layer 900% elongation graft, despite an overall thinner wall dimension.
  • the superior strength of the composite graft is demonstrated by the higher elongation capable of being borne by the graft prior to failure.
  • the lower suture hole elongation, indicative of a smaller tear being caused by suturing and tensioning at a fixed value of 100 grams is clearly demonstrated for the graft prepared by the method of the current invention.
  • Tubular graft 20 is a composite structure similar to graft 10 described above.
  • Graft 20 includes an outer tube 22 and an inner tube 24 formed generally in the manner described above.
  • an additional layer may be employed in combination with outer tube 22 and inner tube 24.
  • an additional layer 26 may be employed between inner tube 24 and outer tube 22.
  • Layer 26 may include a helical wrap of ePTFE tape 27 placed over inner tube 24.
  • the additional layer 26, however, may also exist as a sheet, film, yarn, monofilament or multi filament wrap, or additional tube.
  • the additional layer 26 may consist of PTFE, FEP, or other suitable polymer composition to obtain the desired performance characteristics.
  • Layer 26 may be used to impart enhanced properties of porosity and/or strength to the composite graft 20.
  • an additional layer 26 of ePTFE tape 27 having a low IND and wrapped orthogonally to the length direction of graft 20 would increase the radial strength of the resultant composite graft.
  • a layer of ePTFE having a high IND would increase the porosity of the composite structure thereby further promoting cell endothelization and/or tissue ingrowth.
  • layer 26 is disposed between inner tube 24 and outer tube 22, and functions as an intermediate layer therein between. It is further contemplated that the additional layer may be employed over outer tube 22, or an additional layer may be used both over outer tube 22 and over inner tube 24.
PCT/US1997/001720 1996-01-22 1997-01-22 Improved ptfe vascular graft and method of manufacture WO1997025938A1 (en)

Priority Applications (6)

Application Number Priority Date Filing Date Title
JP9526318A JPH11504548A (ja) 1996-01-22 1997-01-22 改良ｐｔｆｅ人工血管およびその製造方法
DE69733122T DE69733122T2 (de) 1996-01-22 1997-01-22 Gefässtransplantat aus ptfe und verfahren zu dessen herstellung
AT97904915T ATE293935T1 (de) 1996-01-22 1997-01-22 Gefässtransplantat aus ptfe und verfahren zu dessen herstellung
CA002243951A CA2243951C (en) 1996-01-22 1997-01-22 Improved ptfe vascular graft and method of manufacture
EP97904915A EP0879029B1 (de) 1996-01-22 1997-01-22 Gefässtransplantat aus ptfe und verfahren zu dessen herstellung
AU17582/97A AU711304B2 (en) 1996-01-22 1997-01-22 Improved PTFE vascular graft and method of manufacture

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US08/588,052 US5800512A (en) 1996-01-22 1996-01-22 PTFE vascular graft
US08/588,052 1996-01-22

Publications (1)

Publication Number Publication Date
WO1997025938A1 true WO1997025938A1 (en) 1997-07-24

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Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US1997/001720 WO1997025938A1 (en) 1996-01-22 1997-01-22 Improved ptfe vascular graft and method of manufacture

Country Status (8)

Country Link
US (4) US5800512A (de)
EP (1) EP0879029B1 (de)
JP (1) JPH11504548A (de)
AT (1) ATE293935T1 (de)
AU (1) AU711304B2 (de)
CA (1) CA2243951C (de)
DE (1) DE69733122T2 (de)
WO (1) WO1997025938A1 (de)

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CA2243951A1 (en) 1997-07-24
AU1758297A (en) 1997-08-11
AU711304B2 (en) 1999-10-07
JPH11504548A (ja) 1999-04-27
US20070244539A1 (en) 2007-10-18
DE69733122T2 (de) 2005-12-01
US5800512A (en) 1998-09-01
US6001125A (en) 1999-12-14
CA2243951C (en) 2002-09-10
US6036724A (en) 2000-03-14
EP0879029A1 (de) 1998-11-25
ATE293935T1 (de) 2005-05-15

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